1981 XJ650 Rebuild list

I've seen a list posted on this forum of all the necessary items/repairs that restoring an old xj650 might need, but I can't find it. It was along the vein of "If you're gonna clean your carbs in hopes of the bike running well make sure you do these repairs/replacements/cleanings or you'll probably be wasting your time."
Can somebody please provide a link if they know where it is.
Thanks.

 

Link to that thread (and more) is in my signature.

 

Awesome! That's the one.
Thanks brother.

 

I’m new to wrenching and xj bikes but I’ve got one and I’m gonna give it a go.
Is it safe to say that starting a carb rebuild would start with removing it, inspecting it, and then ordering parts? I’m confident that the thing has been neglected terribly. When I got the bike it ran but wouldn’t exceed 80km or go over 4000 rpm. After changing the filthy oil/filter and running some seafoam through it, it sounded amazing and seemed to run much smoother for about 5 blocks before it bogged down and stalled. This happened 3 times at faster intervals until it would no longer start and idle.
Any advice is appreciated.

 

Yes, remove and disassemble the carbs including the breaking the rack in order to get the throttle shaft seals. Once everything is apart and clean, inspect all of the hard parts for wear then place your order with Len. For reference, almost everything "soft" (o-rings, gaskets, seals) within the carbs need to be replaced. The only exception is the diaphragm on the slide, which may in fact need to be replaced but the link in K-moe's signature will tell you how to check them out. Search out the "Church of Clean" information for how best to go about getting your carbs in top condition.
While the carbs are off, check and adjust your valves. Don't skip this step. If you are this far into the carbs then you have the confidence to pull the valve cover and get this step taken care of. You're bike and your blood pressure will thank you.
There's so very much more to making one of these bikes safe and reliable, not to mention "rebuilt", but if step 1 is just getting the engine running smoothly this will go a long way to that accomplishment.

Good luck!

 

Dammit I cannot believe I misused "You're" instead of "Your", I must resign my internet card for a few days for this. Why can't I edit my post...?

 

Just as a data point, I did not break my XJ650 rack. I completely disassembled per Rick-co-Matic's instructions and cleaned all the little rust pieces out of the carb nooks and crannies. I boiled the carb bowls in lemon juice and cleared out the enrichment passages. Checked the float levels with windshield washer and the 4 hoses. Bench sync and then vacuum sync.

I did not require any purchase of parts. Everything cleaned up and went back into the carbs. The idle screws are delicate but I was able to get them all out.

My 82 XJ650 was fairly rusty and neglected. All of the rusty carb fasteners went into the boiling lemon juice as well. They come out completely rust free.

My opinion is that if the rubber parts are not leaking, don't break the rack. Just my opinion. I put 5000 miles on the bike after the carb rebuild with no gasoline leaks from the seals.

 

Just an FYI Throttle Shaft Seals do not leak gas. They are a source for slight vacuum leaks which effect Idle Quality and off idle throttle response.
30 plus year old throttle shaft seals and o-rings on the idle screws are toast anyway you cut it. You can get by not replacing them but its not going to right.
I was not a beleiver in those little seals but after rebuilding a few carb sets and seeing and hearing the results I will never skip that step again.
Its the same as carb boots. Cracked and stiff as a petrified tree , people still mess with them and pulling the carbs several times makes it even worse.
New ones the carbs slip right in and no vacuum leaks from the cracks, easy as pie to slip them in and out.
I know they are an investment but there is nothing better than a XJ that runs right.